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OVERVIEW OF WELDING
PROCEDURES
FLUX CORED ARC WELDING (FCAW)
AND GMAW PROCEDURES
For each wire feed speed, a corresponding voltage
has been preprogrammed into the machine by welding
experts. This preprogrammed voltage is the best
average voltage for the procedure at the given wire
feed speed. If the wire feed speed is changed on the
wire feeder, the voltage automatically changes with it.
In some cases, the operator may want to change the
preprogrammed voltages; for example, to compensate
for cable and fixture voltage drops. The preset volt-
ages can be adjusted on the wire feeder’s Voltage dis-
play. When a change is made to the voltage at one
wire-feed speed, this change is applied to all other
wire feed speed settings. For example, if the operator
turns up the voltage by 10 percent, the machine auto-
matically increases the preset voltages at all the other
wire feed speeds by 10 percent. In the GMAW FCAW
process, the display shows the Procedure Description,
WFS and Preset Voltage. The preset voltage which
was programmed at the factory, may be changed on
the wire feeder voltage display. Note that, if you
change the default preset voltage up or down, a
respective “ ” or “V” sign will be displayed after the
preset value. When the gun trigger is pulled, note that
the display changes to show WFS, Actual Arc Voltage
and Actual Arc Current. See Table B.5 for display
summary.
PULSE PROCEDURES
In these procedures, the actual voltage greatly
depends on the waveform used. The peak currents,
background currents, rise times, fall times, and pulse
times all affect the actual voltage. The actual voltage
for a given wire feed speed is not directly predictable
unless the waveform is known. In this case, it is not
practical to preset an actual voltage for the procedure.
Instead, an arc length adjustment is provided. The
machine “knows” what the best arc length is at the
given wire feed speed but allows the operator to
change it.
The arc length can be adjusted between 0.5 and 1.5
on the wire feeder’s Voltage display. An arc length trim
of 1.0 means that no adjustments will be made to the
preset arc lengths. An arc length trim greater than 1.0
increases the preset arc lengths. An arc length trim
less than 1.0 decreases the preset arc lengths. The
arc length adjustment is factored in at all wire feed
speed settings. Refer to Table B.6 for summary of arc
length trim.
Increasing the arc length by 10 percent at a given wire
feed speed also increases all the other arc length set-
tings of the procedure by 10 percent. In the GMAW
Pulse process, the display shows the Procedure
Description, WFS and Arc Length Trim. Arc length trim
is programmed to a default at the factory and may be
adjusted on the wire feeder. When the trigger is
pulled, the WFS, Actual Arc Voltage and Actual Arc
Current are displayed.
STICK/TIG
PROCEDURES
Stick welding can be performed with the Power Wave
by attaching a remote control kit to the 6-pin amphe-
nol on the front of the machine. The K941-1 remote
control kit is recommended. Select the stick process
from either the GMAW Pulse, GMAW FCAW, stick
process selection overlay, or recall it from a previously
stored memory location with a Weld From Memory
overlay. When this process is selected, the Power
Wave reads the current (amps) setting from the remote
control kit. It also controls the output of the machine
based on the position of the Output Terminals switch,
which is also located on the remote control kit. When
this switch is in the ON position, the output terminals
of the Power Wave are electrically hot. When the
switch is in the OFF position, the output terminals of
the Power Wave are electrically cold and the machine
cannot produce an output. In the stick process, the
LCD display shows Procedure Description, and Preset
Current (SET=). The Current Trim is always equal to 1
(T=1.00). When the trigger is pulled the Preset Current,
Actual Arc Voltage and Actual Arc Current are dis-
played.
See Tables B.3 through B.6 for a summary of the
information discussed above.
WAVE CONTROL
The wave control settings of all procedures can be
changed on the Power Wave GMAW Pulse, GMAW
FCAW, Stick Process Selection Overlay. The wave
control is a setup parameter that may be adjusted
when the welding procedures are set. This feature
provides an easy way to change the arc behavior with-
out creating a new procedure. The wave control set-
ting of a procedure limits the speed at which the cur-
rent waveform of that procedure can change. Typically,
each procedure is programmed to have average wave
control (at the center of the scale).
OPERATION
B-20 B-20
POWER WAVE 450
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